Glass washing machine with broken glass removal system

ABSTRACT

A glass sheet washing machine with a broken glass removal system includes a support, a liquid container or reservoir, a pump, a liquid applicator, and a liquid permeable member. The support supports a glass sheet being washed. The liquid reservoir is positioned below the support. The pump is coupled to the liquid reservoir. The liquid applicator is coupled to the pump. The liquid applicator applies the liquid from the liquid reservoir to wash the glass sheet. Excess liquid falls into the reservoir. The liquid permeable member is positioned between the support and the liquid reservoir to catch pieces of glass to inhibit the pieces of broken glass from falling into the liquid reservoir and is moved to remove the pieces from the glass washing machine.

TECHNICAL FIELD

[0001] The present invention relates generally to glass processingequipment and, in particular, to glass sheet washing machines.

BACKGROUND ART

[0002] Glass sheets or plates are used in the construction of a widevariety of items including doors, windows, furniture, mirrors andinsulating glass units. Typically, a glass sheet or plate is mountedusing an adhesive and/or a sealant. For an adhesive and/or a sealant toproperly adhere to a glass sheet or plate, the glass sheet or plate mustbe clean. As a result, glass sheet washing machines have been developed.

[0003] Known glass sheet washing machines include a top row of brushrollers spaced apart from a bottom row of brush rollers. Sprayers spraya washing or rinsing liquid on each brush roller. A conveyor includesdrive rollers positioned adjacent to brush rollers of each row. Theglass sheets are passed through the conveyor with one large face up andone large face down. The top row of brush rollers acts on one large faceof the glass and the bottom row acts on the other large face. Fluidreservoirs or containers are positioned below the conveyor and the brushrollers. Washing or rinsing fluid is pumped from the fluid reservoirs tothe spray nozzles. Excess washing or rising liquid sprayed onto thebrush rollers re-enters the reservoir under the force of gravity torecycle the liquid.

[0004] It is common for glass sheets or plates being washed to break.When the glass sheet or plate breaks, broken pieces of glass fall intothe fluid reservoirs. Typically, the operator of the glass washingmachine will wait until the end of a production shift to remove thebroken pieces of glass from the fluid reservoirs, so production is notinterrupted. Presently, removal of the broken pieces of glass from thereservoirs is a difficult, time consuming, manual operation. Theoperator slides the reservoirs out from under the glass washing machineand “scoops” the broken pieces of glass out of the reservoirs with ashovel or net. A tray or pan can also be placed above the reservoirs tocollect the broken glass. This requires dedicated floor space around themachine to be able to remove the trays.

[0005] What is needed is a system for inhibiting pieces of a brokensheet or plate of glass from falling into fluid reservoirs and easilyremoving the broken pieces from the glass washing machine.

DISCLOSURE OF INVENTION

[0006] The present disclosure concerns a glass sheet or plate washingmachine. The disclosed washing machine includes a support, a liquidcontainer or reservoir, a pump, a liquid applicator, and a glasscatching web. The support supports a glass sheet being washed. Theliquid reservoir is positioned below the support. The pump is coupled tothe liquid reservoir. The liquid applicator is coupled to the pump. Thepump provides liquid from the reservoir to the liquid applicator. Theliquid applicator applies the liquid from the reservoir to the glasssheet to wash the glass sheet. An excess of the liquid falls back intothe reservoir. The glass catching web is positioned between the supportand the reservoir to catch pieces of broken glass when a glass sheetbeing washed breaks. The glass catching web inhibits pieces of brokenglass from falling into the liquid reservoir.

[0007] In one embodiment, the glass catching web is a liquid permeablemember. The glass catching web may be supported by first and secondrotatable rolls. Rotation of the rolls moves the glass catching web toremove pieces of broken glass that have fallen onto the glass catchingweb.

[0008] In one embodiment, the glass catching web is connected at one endto one of the rotatable rolls and at a second end to the other rotatableroll. The rolls are rotated in one direction to move the glass catchingweb to remove broken pieces of glass. The rolls may then be rotated inan opposite direction to position the glass catching web to catch piecesof a subsequent glass sheet that breaks.

[0009] In an alternate embodiment, the glass catching web is in the formof a continuous belt. The belt is disposed around the first and secondrotatable rolls. The rotatable rolls are rotated, moving the glasscatching web to remove broken pieces of glass. The rotatable rolls maybe constantly driven to continuously remove any pieces of broken glassthat fall onto the glass catching web.

[0010] In one embodiment, the glass catching web is a rubber belt. In analternate embodiment, the liquid permeable member is a wire mesh belt. Atrough may be disposed below the glass catching web for receiving piecesof broken glass.

[0011] In one embodiment, the support is a conveyor that moves glasssheets or plates above the glass catching web. The liquid applicator maycomprise a rotating brush and a spray nozzle. The rotating brush ispositioned along a path of travel of the glass sheet. The rotating brushcontacts the glass sheet as the glass sheet moves through the glasswashing machine. The spray nozzle is positioned to spray liquid onto therotating brush.

[0012] A method of inhibiting pieces of broken glass from entering afluid reservoir of the glass sheet washing machine includes applyingfluid to a glass sheet to wash the glass sheet. A glass catching web isplaced between the glass sheet and a fluid reservoir of the glasswashing machine. Excess fluid is communicated through or past the glasscatching web to the reservoir. When a glass sheet breaks, pieces ofbroken glass are caught with the glass catching web to inhibit piecesfrom entering the fluid reservoir. The glass catching web is moved toremove pieces of broken glass.

BRIEF DESCRIPTION OF DRAWINGS

[0013]FIG. 1 is a side elevational view of a glass washing machine witha broken glass removal system;

[0014]FIG. 2 is a schematic representation of one station of a glasswashing machine with a broken glass removal system;

[0015]FIG. 3 is a top plan view of one station of a glass washingmachine with a glass removal system;

[0016]FIG. 4 is a schematic illustration of a conveyor drive in a glasswashing machine with a broken glass removal system;

[0017]FIG. 5 is a schematic illustration of brush drives in a glasswashing machine having a broken glass removal system;

[0018]FIG. 6 is a schematic representation of reservoirs of a glasswashing machine;

[0019]FIG. 7 is a schematic representation of a liquid permeable beltmounted on rollers above reservoirs of a glass washing machine;

[0020]FIG. 8 is a schematic representation of an elongated glasscatching member connected to rollers above reservoirs of a glass washingmachine;

[0021]FIG. 9 illustrates an elongated glass catching member connected toa roller that is rotatable with a crank;

[0022]FIG. 10 illustrates an elongated glass catching member connectedto a roller that is rotatable with a crank;

[0023]FIG. 11 illustrates flow valves of a glass washing machine;

[0024]FIG. 12 depicts a drive train for rollers of a conveyor;

[0025]FIG. 13 illustrates a glass catching member positioned in ahousing of a glass washing machine;

[0026]FIG. 14 shows drive trains of brushes and conduits to sprayers ofa glass washing machine;

[0027]FIG. 15 illustrates a liquid permeable glass catching member.

BEST MODE FOR CARRYING OUT THE INVENTION

[0028] The present disclosure is directed to a glass sheet washingmachine 10 for cleaning glass sheets 12 or plates. The washing machine10 includes a support 14, a reservoir or container 16, a pump 18, aliquid applicator 20, and a glass catching web 22. In the illustratedembodiment, the glass catching web 22 is a liquid permeable member.Referring to FIG. 2, the support 14 supports a glass sheet 12 beingwashed. The liquid reservoir 16 is positioned below the support 14. Thepump 18 is coupled to the liquid reservoir 16. The liquid applicator 20is coupled to the pump 18. The pump 18 supplies a cleaning liquid 24from the reservoir 16 to the applicator 20. The liquid applicator 20applies the cleaning liquid 24 to the glass sheet 12 to wash the glasssheet 12. Excess liquid 26 falls back into the reservoir 16. The glasscatching web 22 is positioned between the support 14 and the reservoir16 to catch broken pieces of glass 28 when a glass sheet 12 being washedbreaks. The glass catching web 22 inhibits the broken pieces 28 fromentering the reservoir 16.

[0029] Referring to FIG. 1, the illustrated glass washing machineincludes a prewash station 30, a wash station 32, a first rinse station34 and a final rinse station 36. Referring to FIGS. 1-3, in theillustrated embodiment, each station 30, 32, 34, 36 includes a support14, a reservoir 16, a pump 18, and a liquid applicator 20. In theillustrated embodiment, a single glass catching web 22 is used in theglass sheet washing machine 10. The glass catching web 22 spans all fourstations 30, 32, 34, 36 in the illustrated embodiment. The glasscatching web 22 is positioned between the support 14 and the reservoir16 of all four stations 30, 32, 34, 36.

[0030] Referring to FIGS. 1-4, the illustrated support 14 is a conveyor38. The conveyor 38 includes an upper set of rollers 40 and a lower setof rollers 42. The rollers 40, 42 move the glass sheet 12 through thewashing machine 10.

[0031] Referring to FIG. 4, the rollers 40, 42 are driven by a chain 44coupled to a conveyor motor 46. In the illustrated embodiment, therollers 40, 42 for all four stations 30, 32, 34, 36 are driven by asingle chain and a single conveyor motor. The chain 44 engages a gear 48on each of the lower rollers 42 (see FIGS. 4 and 12). The chain 44 ismaintained in engagement with gears 48 on each of the lower rollers 42by idler gears 50 a, 50 b and tensioning guides 52. Each lower roller 42includes a second gear 54 positioned inward of the gear 48. Each of theupper rollers 40 include a gear 56 that meshes the second gear 54 ofeach lower roller 42. The conveyor motor 46 moves the chain 44 along thepath illustrated in FIG. 4 to rotate each of the lower rollers 42. Thesecond gear 54 on each lower roller 42 engages the gear 56 on each upperroller to rotate the upper roller 40. Glass placed in the conveyor 38 ismoved through the washing machine 10 by the rollers 40, 42.

[0032] Referring to FIGS. 2 and 6, each station 30, 32, 34, 36 includesits own reservoir 16. Each reservoir 16 includes the cleaning liquid 24that is applied to the glass sheet in the station that the reservoir isa part of. In the illustrated embodiment, the reservoirs 16 of theprewash station 30, the first rinse station 34 and the final rinsestation 36 contain water. The reservoir 16 in the wash station 32contains a solution of water and a detergent. Each reservoir 16 includesan inlet 60 and an outlet 62. The inlet 60 provides cleaning fluid 24 tothe reservoir 16. The outlet 62 is in communication with the pump 18that supplies the cleaning liquid 24 to the liquid applicator 76.

[0033] Referring to FIG. 2, the reservoir 16 includes a float 64 thatregulates the liquid level in the reservoir 16. As cleaning liquid 24 isremoved from the reservoir, the float 64 moves downward. When the floatreaches a threshold level a valve 66 opens the inlet 60 to add cleaningliquid 24 to the reservoir. As cleaning liquid is added, the float 64moves upward. When the float reaches a threshold value, the valve 66closes to stop flow of fluid 24 into the reservoir 16.

[0034] Referring to FIG. 6, the inlet 60 and spray nozzles of the finalrinse station 36 is coupled to a source of clean water, such as a tap68. Clean tap water fills the reservoir 16 of the final rinse station36, first rinse station 34 and wash station 32. The water from the finalrinse reservoir 16 is recycled into the first rinse station nozzles asglass sheets are washed. The water from the first rinse reservoir 16 isrecycled into the pre wash station nozzles as glass sheets are washed.The water in the wash reservoir 16 is recycled into the wash stationnozzles as glass sheets are washed. In the illustrated embodiment, wateris provided to the reservoir of the first rinse station nozzles from thefinal rinse station 36. A pump 18 provides water from the reservoir 16of the final rinse station 36 to the inlet 60 of the first rinse station34. Similarly, the reservoir of the pre-wash station 30 is filled withwater from the first rinse station 34. A pump 18 provides water from thefirst rinse station 34 to the pre-wash station 30. In this manner, wateris cycled through the final rinse station 36, then the first rinsestation 34 and finally the pre-wash station 30. As should be apparent,the most clean water is contained in the reservoir of the final rinsestation 36, slightly less clean water is contained in the reservoir 16of the first rinse station 34 and less clean water is contained in thereservoir 16 of the pre-wash station 30. The cleaning liquid 24 used inthe wash station is not provided to the reservoirs of the otherstations, because this liquid contains detergent and is heated.

[0035] Referring to FIG. 2, the pump 18 is coupled to the reservoir 16in each station 32, 34, 36. In the illustrated embodiment, the liquidapplicator 20 comprises an upper rotating brush 74 a, a lower rotatingbrush 74 b and spray nozzles 76. The rotating brushes 74 a, 74 b arepositioned along a path of travel defined by the conveyor 38. Therotating brushes 74 a, 74 b contact the glass sheets as they are movedthrough the washing machine 10 by the conveyor 38. The pump 18 providescleaning liquid 24 to the spray nozzles 76. The spray nozzles 76 spraythe cleaning liquid 24 onto the rotating brushes. Referring to FIGS. 2and 3, a first plurality of spray nozzles 76 are positioned to spraycleaning liquid 24 along substantially the entire length of an upperrotating brush 74 a. Likewise, an array of spray nozzles 76 ispositioned to spray cleaning liquid 24 onto a lower brush 74 b alongsubstantially the entire length of the lower rotating brush 74 b.

[0036]FIG. 5 illustrates one way of driving the rotating brushes 74 a,74 b. In the illustrated embodiment, a motor 78 positioned outside thewashing machine 10 drives the brushes 74 a, 74 b (see FIG. 14). A belt80 is positioned around a pulley 82 on the motor 78 and around a pulley84 on an upper brush 74 a. The belt engages a side of a pulley 86 on alower brush 74 b. In this configuration, rotation of the pulley 82 bythe motor 78 in a clockwise direction will rotate the upper brush 74 ain a clockwise direction and rotate the lower brush 74 b in acounterclockwise direction. Similarly, if the pulley 82 is driven in acounterclockwise direction by the motor 78, the upper brush 74 a isdriven in a counterclockwise direction and the lower brush 74 b isdriven in a clockwise direction.

[0037] Referring to FIGS. 1, 4 and 5, the liquid permeable glasscatching web 22 is positioned between the lower brushes 74 b and thereservoir 16 in the illustrated embodiment to catch pieces 28 of brokenglass when a glass sheet 12 being washed breaks. In one embodiment,illustrated by FIGS. 1, 4, 5 and 8, the glass catching web is anelongated belt 88 supported by first and second rotatable rolls 90, 92.In the exemplary embodiment, the rotatable rolls 90, 92 are elongatedshafts that extend across the entire width of the glass washing machine10. In the exemplary embodiment, each rotatable roll 90, 92 is connectedto the glass washing machine 10 by flange bearings 94 that allowrotation of the rotatable rolls 90, 92. In the embodiment illustrated byFIGS. 1, 4, 5 and 8, a crank 96 is mounted to an end of each of therotatable rolls 90, 92 (see FIG. 9). In the illustrated embodiment, therotatable rolls 90, 92 are spaced apart such that the elongated beltspans substantially all of the reservoirs 16 in the stations 30, 32, 34,36. In one embodiment, illustrated in phantom in FIG. 1, the rotatableroll 90 is positioned above the reservoir 16 of the pre-wash station 30.The rotatable roll 90 may also be positioned outward of the glasswashing machine 10 such that all of the reservoirs 16 are covered by thebelt 80. For example, the rotatable roll may be mounted as illustratedat 90′ of FIG. 1.

[0038] The rotatable roll 92 is positioned outside the glass washingmachine 10 in the illustrated embodiment. In one embodiment, theelongated web or belt of liquid permeable material is longer than thedistance between the first rotatable roll 90 and the second rotatableroll 92. The extra length of the belt 88 may be rolled onto the firstrotatable roll 90 by turning the crank 96 on the first rotatable roll90. The elongated belt 88 is maintained in this position until a glasssheet breaks and broken pieces 28 of glass fall onto the elongated belt88. The elongated belt 88 inhibits broken pieces 28 of glass fromfalling into the reservoir 16. The crank 96 on the second rotatable roll92 may be turned to roll the elongated belt 88 onto the second rotatableroll 92. As the elongated belt 88 is rolled onto the second rotatableroll 92, broken pieces of glass 28 on the elongated belt 88 are movedtoward the second rotatable roll 92 and fall off the elongated belt 88into a trough 98. In the exemplary embodiment, the length of elongatedbelt 88 that can be rolled onto the second rotatable roll 92 is as longor longer than the distance between the first and second rotatable rolls90, 92 so that any glass that falls onto the elongated belt 88 can beremoved from the glass washing machine 10 by rotating the crank 96 onthe second rotatable roll 92. After the glass pieces 28 are removed fromthe elongated belt 88 by turning the crank 96 on the second rotatableroll 92, the crank 96 on the first rotatable roll 90 is turned to windthe elongated belt 88 back onto the first rotatable roll 90 so thatpieces of the next glass sheet or plate that is broken can be removed byrotating the second rotatable roll 92.

[0039]FIG. 7 illustrates a glass catching web 22 of a second embodiment.In this embodiment, the liquid permeable member 22 is a continuousliquid permeable belt 100 disposed around first and second rotatablerolls 102 a 102 b. Rotation of the rotatable rolls 102 a, 102 b movesthe continuous belt 100 to remove broken pieces of glass 28 and drop thebroken pieces of glass 28 into the trough 98. The rotatable rolls 102 a,102 b may include a crank 96. In this embodiment, the glass washingmachine operator turns the crank 96 when a glass sheet breaks to removepieces of broken glass 28 from the glass washing machine 10. In oneembodiment, the rotatable rolls 102 a, 102 b are coupled to a motor 104that drives the rotatable roll 102 a to remove broken pieces of glass28. The motor 104 may be selectively turned on to remove broken piecesof glass 28 or may be run constantly so that any broken pieces of glass28 are automatically removed. In one embodiment, a sensor may beprovided that determines when a glass sheet breaks and automaticallyturns the motor 104 on for a period of time to remove any broken pieces.

[0040] The illustrated glass catching web is a liquid permeablematerial. Suitable liquid permeable materials include a perforatedrubber sheet and wire mesh.

[0041] In one embodiment, first and second air knives are positionedabove and below the conveyor 38 near an exit of the glass washingmachine for drying washed glass sheets or plates. One suitable air knifeis described in U.S. patent application Ser. No. 10/352,010 entitled“Air Knife and Conveyor System,” in the name of Robert Sheperd et al.owned by Glass Equipment Development, filed on Jan. 27, 2003, whichclaims priority from provisional patent application Serial No.60/365,500, filed Mar. 18, 2002 and is incorporated herein by referencein its entirety.

[0042] Although the present invention has been described with a degreeof particularity, it is the intent that the invention include allmodifications and alterations falling within the spirit and scope of theappended claims.

We claim:
 1. A glass sheet washing machine, comprising: a) a support fora glass sheet being washed; b) a liquid container positioned below saidsupport; c) a pump coupled to said liquid container; d) a liquidapplicator coupled to said pump for applying a liquid from said liquidcontainer to wash said glass sheet, wherein an excess of said liquidfalls into said liquid container; and e) a moveable web positionedbetween said support and said liquid container to catch pieces of abroken glass sheet to inhibit said pieces from entering said liquidcontainer and remove the pieces from the glass washing machine.
 2. Themachine of claim 1 wherein said web is liquid permeable.
 3. The glasswashing machine of claim 1 wherein said web is supported by first andsecond rotatable rolls, rotation of said rolls moves said web to removesaid broken pieces of glass from a region below said applicator.
 4. Theglass washing machine of claim 1 wherein a first end of said web isconnected to a first rotatable roll and a second end of said web isconnected to a second rotatable roll, rotation of said rolls moves saidweb to remove said broken pieces of glass from a region below saidapplicator.
 5. The glass washing machine of claim 1 wherein said web isbelt disposed around first and second rotatable rolls, rotation of saidrolls moves said web to remove said broken pieces of glass from a regionbelow said applicator.
 6. The glass washing machine of claim 1 furthercomprising a trough disposed below said web for receiving said brokenpieces of glass.
 7. The glass washing machine of claim 1 wherein saidweb is a perforated belt.
 8. The glass washing machine of claim 1wherein said web is a wire mesh belt.
 9. A method of inhibiting piecesof a broken glass sheet from entering a fluid container of a glass sheetwashing machine and removing the pieces from the machine comprising: a)applying a fluid to a glass sheet on a support to wash said glass sheet;b) placing a web between a glass sheet support and a fluid container ofsaid glass washing machine; c) communicating excess fluid applied tosaid glass sheet through said web to said container; d) catching piecesof a broken glass sheet with said web to inhibit said pieces fromentering said fluid container; and e) moving said web with respect tosaid machine to remove said pieces from said machine.
 10. The method ofclaim 9 wherein said web is supported by first and second rotatablerolls, said rolls are rotated to move said web to remove said brokenpieces of glass from said glass washing machine.
 11. The method of claim9 wherein a first end of said web is connected to a first rotatable rolland a second end of said web is connected to a second rotatable roll,said rolls are rotated to move said web and remove said broken pieces ofglass from said glass washing machine.
 12. The method of claim 9 whereinsaid web is a belt disposed around first and second rotatable rolls,said rolls are rotated to move said web and remove said broken pieces ofglass from said glass washing machine.
 13. The method of claim 9 whereinmoving said liquid permeable member removes said broken pieces of glassand drops said broken pieces of glass into a trough disposed below saidweb.
 14. A glass sheet washing machine, comprising: a) a conveyor thatprovides support and defines a path of travel for a glass sheet beingwashed; b) a rotating brush positioned along said path of travel suchthat said rotating brush contacts said glass sheet as said sheet movesalong said path of travel; c) a spray nozzle positioned to spray aliquid onto said rotating brush; d) a liquid container positioned belowsaid conveyor and said rotating brush; e) a pump coupled to said liquidcontainer that provides said liquid to said spray nozzle, wherein anexcess of said liquid falls into said liquid container; and f) a liquidpermeable belt positioned below said rotating brush and said conveyorand above said container that catches pieces of a broken glass sheet toinhibit said pieces from entering said liquid container, whereinmovement of said belt removes said broken glass pieces from said glasswashing machine.
 15. The glass washing machine of claim 13 additionallycomprising first and second rotatable rolls that support the liquidpermeable belt, rotation of said rolls moves said liquid permeable beltto remove said broken pieces of glass from said glass washing machine.16. The glass washing machine of claim 13 wherein a first end of saidliquid permeable belt is connected to a first rotatable roll and asecond end of said liquid permeable belt is connected to a secondrotatable roll, rotation of said rolls moves said liquid permeable beltto remove said broken pieces of glass from said glass washing machine.17. The glass washing machine of claim 13 wherein said liquid permeablebelt is disposed around first and second rotatable rolls, rotation ofsaid rolls moves said liquid permeable member to remove said brokenpieces of glass from said glass washing machine.
 18. The glass washingmachine of claim 13 further comprising a trough disposed below saidliquid permeable belt for receiving said broken pieces of glass removedfrom said glass washing machine.
 19. The glass washing machine of claim13 wherein said liquid permeable belt is made from perforated rubber.20. The glass washing machine of claim 13 wherein said liquid permeablebelt is made from wire mesh.
 21. A method of removing pieces of a brokenglass sheet from a glass sheet washing machine, comprising: a) applyinga fluid to a rotating brush; b) moving a glass sheet into contact withsaid rotating brush to wash said glass sheet; c) placing a fluidpermeable belt between said rotating brush and a fluid container of saidglass washing machine; d) communicating excess fluid applied to saidbrush through said belt to said container; e) catching pieces of abroken glass sheet with said liquid permeable belt to inhibit saidpieces from entering said fluid container; and f) moving said belt toremove said broken glass pieces from said glass washing machine.
 22. Themethod of claim 21 wherein said liquid permeable belt is supported byfirst and second rotatable rolls, said rolls are rotated to move saidliquid permeable belt to remove said broken pieces of glass from saidglass washing machine.
 23. The method of claim 21 wherein a first end ofsaid liquid permeable belt is connected to a first rotatable roll and asecond end of said liquid permeable belt is connected to a secondrotatable roll, said rolls are rotated to move said liquid permeablebelt and remove said broken pieces of glass from said glass washingmachine.
 24. The method of claim 21 wherein said liquid permeable beltis disposed around first and second rotatable rolls, said rolls arerotated to move said liquid permeable belt and remove said broken piecesof glass from said glass washing machine.
 25. The method of claim 21further comprising moving said liquid permeable belt to remove saidbroken pieces of glass and drop said broken pieces of glass into atrough disposed below said liquid permeable belt.